Fury 125 Ensamblaje 4fu48

FURY 125 FURY 125R

Motorcycle Assembly & Preparation Manual

Foreword In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most commonly removed parts have a direct bearing on a vehicle's reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needles warranty claims and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers. This Assembly and Preparation Manual explain step by step procedures of the following item for all Kawasaki Fury125.

1. Uncrating 2. Assembly 3. Preparation

The selling dealers assumes sole responsibility for any unauthorized modifications prior to sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale. Whenever you see the following symbols need their instruction! Always follow safe operating and maintenance practice.

!

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. !

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE NOTICE is used to address practices not ralated to personal injury.

NOTE This note symbol indicates points of particular ti l i t interest t for f more efficient ffi i t and d convenient operation.

Kawasaki Motor Philippines Corporation accepts no liability for any inaccuracies or omissions in this publication, although every possible measure has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without notice.

Table of Contents Uncrating ..........................................................................................4 Opening Crate....................................................................................4 Parts Check ......................................................................................5-6 Assembly ............................................................................................7 Handlebar .........................................................................................7 Front Fender .....................................................................................7 Front wheel Installation.......................................................................8 Brake Disc Cleaning ...........................................................................8 Rear View Mirrors ( Left and Right) ....................................................9 Preparation ........................................................................................10 Battery Service .................................................................................10 Battery Activation .................................................................................11-12 Front Brake Fluid ................................................................................13 Rear Brake Fluid. .................................................................................14 Drive Chain ........................................................................................15 Rear Shock Absorber ..........................................................................17 Tire Air Pressures ...............................................................................17 Fuel .................................................................................................17 Engine Oil (4-Stroke) ..................................................................................18 Throtle Grip and Cable ...............................................................................19 Idle Speed Adjustment ...............................................................................19 Choke Lever and Cable ..............................................................................20 Rear Brake Light Switch ..............................................................................20 20 Headlight Aim .............................................................................................20 Fastener Check .............................................................................................21-22 Standard Torque Table ................................................................................23 Test Ride the Motorcycle .............................................................................23 A & P Check List ...........................................................................................23

UNCRATING

Uncrating Opening Crate !

WARNING

Crates have sharp edges and may have nails or screws that can cause cuts and injury. Always wear protective gloves, boots and eye protection when uncrating to prevent injury.

4

NOTICE When you remove the crate bracket from the motorcycle, be careful not to drop any parts and bracket onto the fuel tank and other components, and not to scratch the fuel tank by the crate bracket. This could dama-ge the fuel tank or components. Remove first the two lower flange bolts (D= 8, L=25) at the steering stem and discard it. Remove the two upper bolts (D= 8, L=60 ) and washer (D=24.5) to take off the crate bracket and foam pad and discard them.

A

D

C

!

B

WARNING

The steel crate plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection when uncrating to prevent injury.

A. Upper FlangeBolt (D= 8 , L=60 ) B. Lower FlangeBolt (D= 8 , L=25 ) C. Crate Bracket D. Washer (D=24.5 ) Remove the top and sides of the crate.

Clear a space about 6m (20ft) square to give your self plenty of space to work. Place the crate upright on its base. Remove the parts box.

UNCRATING

5

Prats Check Open the parts box, and check the parts against the illustrations. There may be minor differences between these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in millimeters, and L = length in millimeters. 1

3

2

UNCRATING

No.

Part Name

Qty.

Remarks D = 8 , L = 50

CLAMP CLAMP BOLT-FLANGED

4 2 2 4 1 1 1 1 5 4 1 1 2

4

BATTERY ELCTROLYTE,

1

12 V 3 Ah

5

OWNERS MANUAL

1 1

1 2

3

HANDLEBAR MOUNTING BOLTS SPACER PLUGS PLUGS FRONT WHEEL PIN-COTTER COLLAR FRONT FENDER COLLAR SCREW

TOOL KIT

D = 30 D = 14.5

D = 24 , L = 24.5 D = 16 D = 6 , L = 14 L = 78.8 D = 6 , L = 16

6

ASSEMBLY

7

Install the front fender on the fork legs, and install the collar (D=16)(4) with screw(D=6, L=14) (4) at the left and right of the fork legs.

Assembly Handlebar Handlebar Installation

C

Install the right handlebar with the mounting bolts (D = 8 , L = 50) (2) in place.

D

B A

A. Plastic Plugs (D=14) (4) , (D=30) (2) B. Socket Bolt (D = 8 , L = 50) (4) C. Left and Right Handlebar D. Spacers I t ll fi Install firstt the th spacer and d th then th the lleft ft handlebar in the same manner as the right handlebar.Tighten the left and right handlebar mounting bolts to the specified torque. Torque: 23 N·m (2.3 kgf·m, 17 ft·lb) Push the plastic plugs (D=14)(4) into the handlebar mounting bolts and Install the platic plug (D=30)(2) to left and right handlebar.

A. Boltflange (D=6,L=16) B. Collar (D=16) and Screw (D=6,L=14) C. Front Fender D. Clamp Install the flange bolt (D=6,L=16)at the right side with collar (D=16) inside of front fender, and install the clamp cable guide holder at the right i t ll speedometer install d t cable. bl

A B

Front Fender Front Fender Installation Install the front fender with its facing forward. B

C

A. Speedometer Cable B. Clamp Install the front brake hose clamp on the left side(L = 78.8) with flangebolt (D=6, L=16) inside of the front fender and then tighten it. A B

A

A. Front Fender B. Forward C. Back

A. Brake Hose B. Clamp

ASSEMBLY

8

Front Wheel Installation Lift the motorcycle off the crate base and the motorcycle with a suitable stand or jack to install the front wheel.

D

Discard the crate base. C

B

C E

B

A

A. Front Axle B. Case-Assy-Meter C. Axle Nut D. Collar E. Pin-Cotter

A

A. Axle Nut B. Front Axle C. Pin-Cotter Loosen the left axle nut and remove the front axle. Check the wheel rotation mark on the front tire.

NOTE The direction of the wheel is shown by an arrow on the front tire. Install the wheel so that the ratation mark coincides with wheel ratational direction.

Tigten the front axle nut (D= 17) to the spe-cified torque and install the pin-cotter.

Torque: 48 N·m (4.9 kgf·m , 35 ft·lb) !

WARNING

It may take several application of the brake pads contack the disc,, lever before the brake p which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever is obtained by pumping the lever unit the pads are against the disc.

A B

C

Brake Disc Cleaning Clean the front brake disc using oilless solvent. !

WARNING

An anticorrosive treatment applied to the brake discs will increase braking distance and can cause an accident resulting in se-rious injury or death. Remove the anticor-rosive treatment using an oilless solvent. A. Front Wheel B. Arrow C. Rotation Fit the axle collar on the left sides of the front wheel hud. The collar are identical. Position the front wheel assembly between the fork leg. Insert the front brake disk between the brake pads of the caliper. Insert the front axle from the right side of the wheel and push it completely through.

ASSEMBLY

9

NOTICE

Rear View Mirror (Left and Rigth) Conventional Type (Single Nut) Loosen the lucknut completely. Screw the rear view morror in completely, and then back it two turns out. Turn the mirror stay to assure visibility to the rear with the operator sitting on the motorcycle and tighten the locknut securely. Adjust the rear view mirror by slightly moving only the mirror portion of the assembly. A

Do not force to tighten and / or loosen the upper hexagonal area (adapter) with a spanner or wrench. Disassembly of this area is not possible. Non-permanent locking agent is already applied to the threads of this inner area. Forcible loose- ning may damage the adapter and/or the turning mecha-nism of the stay. Turn the stay to assure visibility to the rear with the operator sitting on the motorcycle. Adjust the rear view mirror by slightly moving only the mirror portion of the assembly.

B A B

A. Locknut B. Rear View Mirror (Right) Installation and adjustment of the left side mirror is common with the right side. Follow the procedure specified for the right side.

Turning Stay Type Screw the mounting area of the right rear view mirror into the holder all the way, and tighten the lower hexagonal area securely.

B

C A

A. Lower Hexagonal Area for Tightening B. Upper Hexagonal Area (Adapter) C. Rear View Mirror (Right)

A. Stay B. Mirror Installation and adjustment of the left side mirror is common with the right side. Follow the procedure specified for the right side.

PREPARATION

Preparation Battery Service

10

Seat Unlock Insert the ignition key into the switch ignition and turn counterclockwise to open the seat.

The battery used in this motorcycle is a sealed type and never needs to be refilled. Follow the procedure for activating a new battery to ensure the best possible battery performance. A

Activating the battery requires two steps, filling the battery with electrolyte , and charging. Read the electrolyte safety label and the following procedure carefully before activation.

NOTICE Incorrect Battery Activation will reduce battery performance and service life. Be sure to strictly follow the Battery Service instructions in this Manual.

B

A. Seat B. Seat Lock

Battery Removal Take the battery out of the battery case.

Make sure to use the electrolyte y packed p in the crate with the unit. Make sure that the model name of the electrolyte container matches the model name of the battery. These names must be the same. Battery Model Name for: AX125A/B: YTX4L-BS

A. Model Name of the Electrolyte B. Model Name of the Battery

NOTICE Sealed battery electrolyte has a higher cancentration of sulfuric acid. Each con-tainer contains the proper amount of electrolyte for its specific battery. Insu- fficient or incorrect electrolytre will reduce battery performance and service life. Electrolyte over capacity can lead to battery cracking or leaking and result in corrosion damage to the vehicle.

E

A. Rubber Band B. Negative (-) Cable C. Terminal Cap D. Positive (+) Cable E. Battery Clean the terminals.

NOTICE Be sure to disconnect the negative (-) cable first.

Battery Specification Make

Yuasa

Battery Type Battery Capacity

YTX4L-BS 12 V 3 Ah

PREPARATION

11

Battery Activation Filling the Battery with Electrolyte

NOTICE Do not remove the alluminum sealing sheet [A] from the filler ports [B] until just prior to use. Be sure to used the dedica-ted eloctrolyte container for correct elec-trolyte volume.

Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery. Hold the container level, push down the break the seals of all six cells. You will see air bubbles rising into each cell as the port fill.

NOTE Do not tilt the electrolyte container.

Place the batterry on the a level surface. Check to see that the sealing sheet [A] has no peeling, tears, or holes in it. Remove the sealing sheet [A].

NOTE The battery is vacuum sealed. If the sealing sheet has leaked air into the battery,it may required longer initial charge.

Remove the electrolyte container from the vinyl bag. Detach the strip of caps [A] from the con- tainer and set asidem, these will be used later to seal the battery.

NOTE Do not pierce or otherwise open the sea-led cells [B] of the electrolyte container. Donot attemp to separate individual cells.

Check the elctrolyte flow. If no air bubbles [A] are coming up from the filler ports, or if the container cells have not emptied completely, p y tap p [B] [ ] the container a few times.

Keep the container in a place for 20 minutes or more. Don't remove the container from the battery untill it's empty, the battery requires all the electrolyte from the container for proper operation.

NOTICE Removal of the container before it is completely empty can shorten the sevice life of the battery. Do not remove the elec trolyte container until it is completely empty and 20 minutes have elapsed. Gently remove the container from the battery. Let the battery sit for 30 minutes prior to charging to allow the electrolyte to permeate into the plate optimum performance.

PREPARATION

NOTE Charging the battery immediately after filling can shorten service life. Let the battery sit for at least 30 minutes after filling.

Initial Charge Place the strip of caps [A] loosely over the filler ports.

12

NOTICE Once the strip of caps [A] is installed on- to the battery, never remove the caps, nor add water or electrolyte to the battery.

NOTE To ensure maximum battery life and customer satisfaction, is recommended the battery be load tasted at three times its amphour rating for 15 seconds. Re-check valtage and if less than 12.8Volt repeat the charging cycle and load test. If still bellow 12.8 V the battery is effective.

Battery Instalation Newly activated sealed batteries requred an initial charge.

Standard Charge 0.4 A x 5 ~ 10 hours If using a recommended battery charger, follow the charger's th h ' iinstructions t ti ffor newly l activated ti t d sealed battery.

Kawasaki- recommended chargers: Opimate III Yuasa 1.5 Amp Automatic Charger Battery Mate 150-9

Turn the ignition switch OFF. Visualy inspect the surface of the battery container. If any signs of cracking or electrolyte leakcage fron the battery, replace it. Apply a little grease on the terminals to prevent corrosion. Connect the positive (+) cable first first, and cover the terminal with the cap. Connect the negative (-) cable. Hook the rubber band.

If the above chargers are not available, use equivalent one.

NOTE Charging rates will vary depending on how long the battery has been stored, temperature, and the type of the charger used. Let battery sit 30 minutes after initial charge, then check voltage using voltmeter. If it is not at least 12.8 V, repeat charging cycle. After charging is complete, press down firmly with both hands to seat the strip of caps [A] into the battery (don't pound or hammer) When properly installed, the strip of the caps will be level with the top of the battery.

A. Rubber Band B. Negative Cable (-) C. Cap D. Positive Cable (+)

PREPARATION

13

Front Brake Fluid Front Brake Fluid Level Inspection With the front brake fluid reservoir held horizontaly, check that the fluid lavel is above the lower level line.

Operate the brake lever several times. If it feel spongy, there might be air in the brake line. If necessary,bleed the air in the front brake line.Also check for fluid leakage around the fitings and bleed the air in the front brake line.

Front Brake Line Air Bleeding Remove the reservoir cap and diaphragm, and that there a plenty of fluid in the reservior.

A. Front Brake Fluid Reservoir B. Lower Level Line C. Upper Level Line If the fluid level is lower than the lower level line, fill the brake fluid to the upper level line. Loosen the screws to remove the front brake fluid reservoir cap and diaphragh diaphragh. Fill the reservoir to the upper level line with DOT3 or DOT4 brake fluid. Inside the front brake reservior is a stepped line showing the upper level line.

NOTE Hold the reservior horizontal by turning the handlebar when checking brake fluid level. !

WARNING

NOTE The fluid level must be checked several times during the bleeding operation and replenished as necessary. If the fluid in the reservior runs completely out any time during bleeding, the bleeding operation must be repeated from the beginning since air will have entered the line. Attach a clear plastic hose to the bleed valve on the front brake caliper and run the other end of the hose into a container. With the reservoir cap off, slowly pump the brake lever several times until no air bubbles can be seen ri through the fluid from the holes at the bottom of the reservoir.This bleed the air from the brake master cylinder end of the line. Pump the brake lever a few times until it becomes hard and then, holding the lever squeezed, quickly open ( turn counterclockwise) and close the bleed valve. Then release the lever. Repeat this operation until no more air can be seen coming out into the plastic hose.

Brake fluid that is contaminated by mois-ture or dirt, mixed or contains air has a lower boiling point and can cause the brake to be ineffective or fail, and it may cause rubber parts to deterioate, resulting in an accident causing injury or death. Never re-use old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Do not mix two types and brands of fluid for use in the brake. Don't leave the reservior cap off for any length of time to avoid moisture contamination of the fluid. Don't add or cha-nge the fluid in the rain or when a strong wind is blowing.

NOTICE Brake fluid quikly ruins painted surfaces. Wipe up any spilled fluid immediately.

A. Open Bleed Valve B. Apply the Brake and Hold It C. Close the Bleed Valve D. Release the Brake

PREPARATION

When air bleeding is finished, check that the fluid level is between the upper and lower lever lines. Install the diaphragm and reservior.

14

B

Tighten the bleed valve to the specified torque.

Torque: 7·8 Nm (0.80 kgf·m, 69 in·lb) Apply the brake fiocefully for a few seconds, and check that the fluid leakage around the fittings.

Rear Brake Fluid Rear Brake Fluid Level Inspection With the rear brake fluid reservior held horizontal, check that the fluid level is between the upper and lower lines.

C A

A. Rear Brake Fluid Reservoir B. Reservoir Cup C. Boltflange Operate the brake pedal several times. If it feels spongy, there might be air in the brake line. If necessary, bleed the air in the rear brake line. Also check for fluid leakage around the fitings.

Rear Brake Line Air Bleeding Remove the reservoir cap and diaphragm, and that there a plenty of fluid in the reservior. A. Reservoir B. Lower Level Line C. Upper Level Line If the fluid level in the reservior is lower than the lower level line, check for the fluid leaks in the brake line, and fill the reservoir. Loosen the cap stopper screw to remove the reservoir to the upper level line with DOT3 or DOT4 brake fluid.

NOTICE Brake fluid quick ruins painted surfaces. Wipe up any spilled fluid immediately.

NOTE First, tighten the rear brake fluid reser-voir cap clockwise by hand until slight resista- nce is felt indicating that the reservoir cap is seated on the reservoir body, then screw to tighten the reservoir cap while holding the brake fluid reservoir body.

NOTE The fluid level must be checked several times during the bleeding operation and replenished as necessary. If the fluid in the reservior runs completely out any time during bleeding, the bleeding operation must be repeated from the beginning since air will have entered the line. Attach a clear plastic hose to the bleed valve on the front brake caliper and run the other end of the hose into a container. With the reservoir cap off, slowly pump the brake lever several times until no air bubbles can be seen ri through the fluid from the holes at the bottom of the reservoir.This bleed the air from the brake master cylinder end of the line. Pump the brake lever a few times until it becomes hard and then, holding the lever squeezed, quickly open ( turn counterclockwise) and close the bleed valve. Then release the lever. Repeat this operation until no more air can be seen coming out into the plastic hose.

PREPARATION

15

B

A

A. Open Bleed Valve B. Close the Bleed Valve When air bleeding is finished, check that the fluid level is between the upper and lower level lines. Tighten the bleed valve to the specified torque.

Torque: 7.8 N·m (0.80 kgf∙m, 69 in∙lb) Install the diaphragm and reservior cap.

NOTE First, tighten the rear brake fluid reser-vior First cap clockwise by hand untill slight resistance is felt indicating that the cap is seated on the reservoir body, then tighten the cap an additional 1/6 turn while holding the brake fluid reservior body.

A. 20~25mm ( 0.79 ~ 1.18 in ) If the drive chain is too tight or too loose, adjust so that the chain slack will be within the standard value. !

WARNING

A chain that breaks or jump off the sprocket could snag on the engine sprocket or lock the rear wheel, severely damaging the mo- torcycle and causing it to go out of control. Inspect the chain for damage and proper adjustment.

Drive Chain Slack Adjustment Remove the cotter pin, and loosen the rear axle nut. Loosen the left and right chain adjus-ter lock nut.

Tighten the reservior cap topper screw. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

Drive Chain Drive Chain Slack and wheel Alignment Inspection Set the motorcycle up on its side stand. Make sure that the drive chain has the specified amount of play, and that the left and right notches are on the same marks or points on tne left and right of the swingarm. !

WARNING

Misalignment of the wheel will result in abnormal wear, and may result in an unsafe riding condition. Be sure the wheel is properly aligned. Rotate the rear wheel to find the position where the chain is tightest, and measure the maximum chain slack by pulling up and puni-shing down the chain midway between the engine sprocket and rear sprocket.

A. Indicator B. Adjuster C. Notch If the chain is too loose, turn out the left and right chain adjusters evenly. If the chain is too tight, turn in the left and right chain adjusters evenly. Turn both chain adjusters evenly until the drivechain has the correct amount of slack. To keep the chain and wheel alignment indicator notches should align with the same marks on each side of the swingarm.

PREPARATION

16

Loosen once and tighten again when the slot goes past the nearest hole.

E B

B

A

C A D

A. Cotter Pin B. Chain Adjuster C. Nut Adjuster D. Axle Nut E. AX125A Model

A. Cotter Pin B. Turning Clockwise

E

C

A. Cotter Pin B. Axle Nut C. Chain Adjuster D. Nut Adjuster E. AX125B Model

NOTE Wheel aligment can also be checked using the straightendge or string method. Tighten both chain adjuster locknuts. Tighten the rear axle nut to the specified torque.

Torque: 53 N∙m (5.4 kgf∙m, 39 ft∙lb) Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary. Install a new cotter pin.

NOTE When inserting the cooter pin if the slots in the nut align with the cotter pin hole in the axle, tighten the nut clockwise up to the next Its should be within 30 degrees.

A. Cotter Pin B. Turning Clockwise Bend the cotter pin over the nut . !

WARNING

A loose axle nut can lead to an accident resulting in serious injury or death. Tighten the axle nut to the proper torque and be sure the cotter pin is installed correctly. Check the rear brake effectiveness.

PREPARATION

17

Rrear Shock Absorder

Fuel

Spring Preload Inspection Check the position of the spring preload on the rear shockk absorber.

STD Spring Preload: 2nd Position

A. Spring Preload Adjuster B. Wrench Turn the preload adjaster to the 2nd position.

Tire Air Pressure To prevent flat-spotting during shipment, the tire are over-inflated before crating. Adjust the tire pressures to the specified values in the front and rear, and make sure to tighten the caps securely.

Tire Air Pressure AX125A/B Front: 175 kPa (1.75 kgf/cm², 25 psi) Rear: 200 kPa (2.00 kgf/cm², 28 psi)

!

WARNING

Gasoline is extremely flamable and can be explosive under certain conditions, creating the potentials of serious burns. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Never fill the tank completely to the top. If the tank is filled completely to the top, heat may cause the fuel to expand and overflow through the vents in the tank cap. After refueling, make sure the tank cap is closed securely. If gasoline is spilled on the fuel tank, wipe it off immediately. Fill the fuel tank with one gallon or four liters of unleaded gasoline. Use a gasoline with a minimum antiknock index rating according to the recommendation of your country. Refer to the following table. The antiknock index is an average of the Research Octane Number (RON) and the Motor Octane Number (MON), as shown in the table.

For US and Canadian Models Octane Rating Method Antiknock (RON + MON) Index ___________ 2

Minimun Rating 87

For Other than US and Canadian Models Octane Rating Method Research Octane Number (RON)

Minimun Rating 91

Check the fuel tank cap, and check for any leaks.

A. Tire Air Pressure Gauge

PREPARATION

18

Engine Oil (4-stroke) Engine Oil Level Inspection NOTE This vehicle's engine is filled with 20W-40 oil from the factory. DO NOT DRAIN and refill the crannkcase before use. Check oil level and drain plug tightness. Engine Oil Drain Plug Torque: 29 N∙m ( 3.0 kgf∙m, 21 ft∙lb) A. Oil Filller Cap B. Oil Level Gauge C. High Level Line D. Low Level Line When replacing the cap, be sure the O-ring is in place, and tighten the cap.

Recommended Engine Oil Type: API, SG, SH, SJ, SL or SM with JASO MA,, MA1 or MA2 Viscosity: SAE 10W-40 A. Engine Oil Drain Plug Park the vehicle on the level ground. Before starting the engine, check that the engine has oil. With the motorcycle held level, check that the engine has oil through the oil level sight gauge in the lower left side of the engine.

NOTICE If the engine is run without oil, it will be severely damaged. Start the engine and run it for several minutes at idle speed. Stop the engine, then wait several minutes until the oil settles. With the motorcycle held level, check the engine oil level through the oil level sight gauge. The oil level should come up between the upper and lower level lines next to the gauge. If the oil level is too high, remove the excess oil through the oil fillter opening, using a syringe or some other suitable device. If the oil level is too low, add oil to reach the correct level. Use the same type of oil that is already in the engine.

Capacity: 0.95 L (1.0 US qt) [when filter is not removed] 1.0 L (1.0 US qt) [when filter is removed] 1.1 L (1.2 US qt) [when the engine is completely dry] Although 10W-40 engine oil is the recommen-ded oil for most conditions, the oil viscosity may need to be changed to accomodate atmosphe-ric condition in your area.

PREPARATION

19

Throttle Grip and Cable Throttle Grip and Cable Inspect the throttle grip free play. If the free play is incorrect, adjust the throttle cables.

Throttle Grip Free Play: 2 ~ 3 mm (0.08 ~ 0.12 in) Check that the throttle grip moves smoothly from full open to close, and the throttle closes quikly and completely in all steering positions by the return properly, check the throttle cable routing, grip free play, and for possible cable damage. Then lubricate the throttle cables.

Loosen the locknut at upper end of the throttle cable, and turn the adjusting nut until the proper amount of throttle grip play is obtained. Tighten the locknut. !

WARNING

Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition. Be sure the cables are routed correctly, properly adjusted and are not damaged in any way.

Idle Speed Adjustment Start the engine, and warn it up thoroughly. Adjust the idle speed by turning the idle adjusting screw.

Idle Speed: 1 300 r/min (rpm)

A. Throttle Grip B. Throttle Grip Play 2~3 mm (0.08 ~ 0.12 in.) Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change. If the idle speed increases, check the throttle grip free play.

Throttle Grip and Cable

A. Idle Adjusting Screw Open and close the throttle a few times to make sure that the idle speed does not change. Readjust if necesary. With the engine idling, turn the handlebar to each side. If handlebar movement change the idle speed, the throttle throttle cable may be improperly adjusted or incorrectly routed, or it may be damage. Be sure to correct any of these conditions before riding. !

WARNING

Operation with damage cable could result in an unsafe riding condition.

A. Locknut B. Adjusting Nut C. Throttle Cable

PREPARATION

Choke Lever and Cable

20

NOTICE

Choke Lever Free Play Inspection B

To avoid damaging the electrical connec-tions inside the switch, be sure that the switch body does not turn during adjust-ment.

Headlight Aim Horizontal Adjustment The headlight beam is adjustable horizontally. If not properly adjusted horizontally,the beam will point to one side rather than straight ahead. A. Choke Cable Free Play B. Choke Lever Check that the choke lever returns properly and that the inner cable slides smoothly. Push that the choke lever back all the way to its released possition. Determine the amount of the choke cable play the choke lever.

Choke Lever Free Play: 2 ~ 3 mm (0.08 ~ 0.12 in.)

A. Bolt

Rear Brake Light Switch Rear Brake Light Switch Adjustment Turn on the ignition switch. The brake light shoult illuminate when the brake pedal is depressed. If it does not, turn the adjusting nut at the rear brake light switch as required. A. Brightest Point

NOTE On high beam, the brightest point should be slightly below horizontal with the motorcycle on its wheels and the rider seated. Adjust the headlight to the proper angle according to local regulation. A. Rear Brake Light Switch B. Adjusting Nut C. Lights Sooner. D. Lights Later.

PREPARATION

21

Fastener Check The torque values listed are for assembly and preparation items only, see the appropriate Service Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery. Also check to see that each cotter pin or circlip is in place. 1

9 16 3 11

2

11 6

4

5 13

15

10

8

14

7

12

PREPARATION

No.

Fastener

Steering Handlebar mounting bolts 1 Steering stem head bolt 2 Brakes Front master cylinder clamp bolts 3 Front caliper mounting bolts 4 Front brake bleed valve 5 Rear master cylinder mounting bolts 6 Rear caliper mounting bolts 7 Rear brake bleed valve 8 Suspension Rear Shock Absorber Mounting Nuts 9 Others Front footpeg bracket bolts (Left and Right) 10 Rear footpeg bracket bolts (Left and Right) 11 Engine oil drain Engine oil drain bolt 12 C tt pins Cotter i or Ci Circlips li Front axle nut cotter pin 13 Rear axle nut cotter pin 14 Rear master cylinder rod cotter pin 15 Rear footpeg pin circlip (Left and Right) 16 Letters used in the '' Remarks '' column means: - G: Apply grease.

Torque N·m

kgf·m

ft·lb

23 44

2.3 4.5

17 32

8.8 25 7.8 25 25 7.8

0.9 2.5 0.8 2.5 2.5 0.8

78 in.lb 18 69 in.lb 18 18 69 in.lb

49

5

36

25 25

2.5 2.5

18 18

29

3

21

-

-

-

22

Remarks

G

-

PREPARATION

Standard Torque Table

Electrical System:

This table relating tigtening torque to thread diameter, list the basic torque for bolts and nuts. Used this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent cleaned threads.

Headlight - check high and low beam. Taillight - check operation. Brake Light - check operation. Turn Signal Lights - check operation. Horn - check operation. Instrument Lights and Inicator Lights - check operation.

General Fasteners

23

Engine Stop Switch Works: Starter Interlock Switch Works: No Unusual Noises: No Fuel, Oil Brake Fluid, Or Coolant Leaks: PREPARATION COMPLETE. !

Test Ride the Motorcycle

WARNING

New tires are slippery and may cause loss of control and injury. A brake-in period of 160 km (100miles) is necessary to establish normal tire traction. During brake-in, avoid sudden and maxi-mum braking and accelaration, and hard cornering.

Complete the test ride checklist.

Control Cables: Throttle control cables must work wiyhout binding in any steering possition.

Steering: Action is free from lock to lock.

Suspension: Check the operation.

Engine: Electric stater works properly and engine starts promptly. Good throttle response and return.

Transmission and Clutch: Smooth operation.

Brakes: Adequate, smooth stopping power, No drag.

A & P Check List Complete the A & P Check List.

Kawasaki Motor Philippines Corporation

Part No. 99939-1335-01